Amp drop for longer cables?

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Was working with a guy yesterday and he was telling me since I run 125 foot stinger 100foot ground that I need to turn my amps up an extra 25 to 30 amps over recommended maxium. I have always run at near the max since I have more drop like on a 7018  3/32s I run at 95 or 100 and 7018 1/8 I run at 150 to 170. What do you guys think? he spewed a bunch of other bs but paid well that just sorta stuck with me though.Vantage 300 kubota ,miller 304 xmt ,lincoln ln 25 pro , ranger 305 G, plenty of other tools of the trade to make the sparks fly.
Reply:That amperage sounds screamin hot already. With no more lead than what you are listing, I believe he is wrong.
Reply:What size cables do you have 225' of?"Where's Stick man????????" - 7A749"SHHHHHH!! I sent him over to snag that MIC-4 while tbone wasn't looking!" - duaneb55"I have bought a few of Tbone's things unlike Stick-Man who helps himself" - TozziWelding"Stick-man"
Reply:Sorry 1/0 for 175 and 50 foot 1 guage whips.Vantage 300 kubota ,miller 304 xmt ,lincoln ln 25 pro , ranger 305 G, plenty of other tools of the trade to make the sparks fly.
Reply:The machine you have won't be affected by the leads you have. I've used that model with 300 ft or more of leads and really didn't notice much change in settings.
Reply:Actually, for the record it's voltage loss that is the issue when dealing with cable lengths at an operating amperages.  In the case of CC welders it the arc voltage that will be affected which will change the weld performance for any given amperage setting.To see the effects in operation, set up a voltmeter at the power source and note the voltage while welding then do the same near the whips at the same amp setting.  Key is to maintain as constant an arc length as possible for accurate results.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:I've never tried it with the actual welder just extension cords on welders and a host of automotive diagnosing but seemingly you should be able to do a voltage drop test which will tell you how much voltage you are losing on each lead. Take one end of multimeter and put in stinger and the other end at the connector on the machine then weld and record the voltage drop that you get. Do same for ground and put end on clamp and end on machine end same lead and that will tell you the drop for that lead. Add the two and you have your total voltage drop on your cables. Test that against some 20' or so of lead and see what the difference is. This way you can take your errors out of the picture. If you have 2 multimeters and a friend that would make it easier obviously so it is also consistant test.Millermatic 252Lincoln 175 plusTA 185tswTA 161stlhypertherm pmax 45Victor torchHenrob torchAn S10 for each day of the week
Reply:Originally Posted by duaneb55Actually, for the record it's voltage loss that is the issue when dealing with cable lengths at an operating amperages.  In the case of CC welders it the arc voltage that will be affected which will change the weld performance for any given amperage setting.To see the effects in operation, set up a voltmeter at the power source and note the voltage while welding then do the same near the whips at the same amp setting.  Key is to maintain as constant an arc length as possible for accurate results.
Reply:I wouldn't worry about having to crank up your amps. This is off a Tweco ground clamp box, and it shows you to be good to 200A.You mentioned 50' of 1 ga whips. I use a 10' - 15' whip on my stinger. For the ground clamp I use a 1' or 2' whip, of 1/0, only because I have quick connects on my cables, which are 50' sections of 1/0. I can't see any reason to have a smaller guage cable or any more length for the ground. (Unless you are Slowhand and you can actually recognize the need to balance your cables!!!)And you should be able to tell wether or not you need more amps once you strike an arc. I think the numbers are just a reference point because my welder might run rod "A" at this amp setting and your other color welder might run rod "A" at 10 - 20A hotter or colder than mine.Last edited by Stick-man; 01-30-2011 at 08:12 PM."Where's Stick man????????" - 7A749"SHHHHHH!! I sent him over to snag that MIC-4 while tbone wasn't looking!" - duaneb55"I have bought a few of Tbone's things unlike Stick-Man who helps himself" - TozziWelding"Stick-man"
Reply:Amps in equals amps out, there is no drop.  A constant current machine will sense current and adjust voltage until you reach the amperage you set on the dial.
Reply:Sounds like black wolfs a bit jaded these daysHobart mega arc 250 Airco dipstick160 air liquide cutting torches arc air gouger and so many more goodiesIf you cant dazzle them with brillants baffle them with bullsh$t
Reply:ok for 1/0 cable you are looking at .0000983 ohms resistance per foot.  Your total length of cable is 225 feet ( there and back)  Ignoring any bad connections you have .0221175 ohms resistanceAt 190 amps welding you will lose ( amps times ohms) 4.21 volts.You are going to lose 4 X 190 = 760 watts of power which is about one horsepower.   A thousand watts used in your toaster is pretty hot but spread out over 225 feet your cables will not overheat.Losing 4 volts will be noticeable to an experienced hand.  The arc characteristics will be slightly different.   A Welder might want to jack up his amperage since in many cases he can't jack up his voltage in order to compensate.
Reply:Originally Posted by Black WolfWhile I agree with some of your information, I strongly disagree with the tone of authority and finality with which it is conveyed.  I am sure that most of us are familiar with the idea of Voltage Drop, but since mose cables are rated by AMPERAGE conducted over the entire length of the circuit, how about we keep it to that?Take note that the chart at the top shows AMPERAGE and distance.  There is NO Mention of the Open Current Voltage rating of the machine supplying the welding current.SMAW (Stick) welding is done on CC - Constant CURRENT - Again, no mention of Voltage.http://www.pacificcabling.com/Specia...rage_chart.htmI used to really enjoy contributing to these forums, but more and more by the day, I find it over-run with Wanna-Be's and "Cyber Experts"Hmmm,,,, Sounds like I should add that to my signature.
Reply:Originally Posted by drami69Sounds like black wolfs a bit jaded these days
Reply:I'd like to think my skin is thick enough Jason and I'm sure you recall I've always made it a point to clarify I'm just a hobby guy and nowhere near a pro weldor of any kind.  As far as I'm concerned it's all good and I for one have always appreciated your posts and insight. MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by 76GMC1500Amps in equals amps out, there is no drop.  A constant current machine will sense current and adjust voltage until you reach the amperage you set on the dial.